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NASA NTRSDate not supplied

Parametric Analysis of Entry Vehicles for Giant Planet Missions

The Planetary Science Decadal Survey has identified Uranus and Saturn as high priori-ty destinations for a flagship and New Frontier missions respectively in the decade 2023-2032. The pro-posed presentation will focus on the entry and descent aspects of the entry vehicles design, considered as part of Giant Planet probe mission concepts, and associated trades for viable trajectory options. Giant Planet Entry Vehicle Parametric Study: Launch vehicle capabilities are evolving and provide an opportunity to increase instrumented probe dimensions. To assess the impact of larger aeroshell designs, a parametric study was conducted to understand the impact on aerothermal environments, TPS options, and TPS mass over a range of 1.0m to 2.0m aeroshell diameters for Uranus and Saturn probe concept missions. The 45° sphere-cone geometry is a legacy configuration that has demonstrated static stability and been used successfully in missions to Venus (Pioneer-Venus) and Jupiter (Galileo). A nose radius of 0.4 m was considered primarily to reduce the heat flux at the stagnation point compared to the smaller radii used in the Venus and Jupiter missions. Representative inertial velocities are chosen from a prior NASA Ames study. Viable entry trajectories to meet concept mission and science objectives were developed using the tool POST2. The newly developed thermal protection material called HEEET (Heatshield for Extreme Entry Environment Technology) was considered in the study. This material, which is at a technology readiness level (TRL) of 6, is highly customizable and available in two varieties: (i) a dual-layer version consisting of recession layer on top of an insulative layer, and (ii) a single-layer version consisting of the insulative layer alone, termed 3- dimensional Mid-Density Carbon Phenolic (3MDCP). Both options were considered for the forward heatshield (the sphere-cone part) in the pre-sent study.

Thermal Protection System↗

NASA NTRS2019

Heat-Cleaned Nextel in MMOD Shielding

Meteoroid and orbital debris (MMOD) shielding can include NextelTM ceramic cloth in the outer layers of the shielding to enhance MMOD breakup. The Nextel fabric can contain size (or sizing) which aids in manufacture of the fabric. Sizing is a starch, oil or waxy material that is added to the rovings and yarns to protect the fibers from being cut or broken during the fabric manufacturing process and by later handling. For spacecraft applications, sizing is removed by heat-cleaning to reduce/eliminate off-gassing during vacuum operations. After the sizing is removed, the fibers in the woven fabric are prone to breakage during handling which reduces fabric strength. Because heat-cleaned Nextel tends to shed fibers that can be irritating to workers, the usual practice for hypervelocity impact tests is to use Nextel with sizing. The reduced strength of heat-cleaned Nextel does not typically effect the performance of MMOD shields with Nextel used in outer layers of the shield, because the density and areal density of the ceramic fibers in the fabric control MMOD breakup (not fabric strength). This paper provides data demonstrating that hypervelocity impact protection performance is not adversely altered for shields containing heat-cleaned Nextel compared to Nextel with sizing.

Christiansen, Eric L.↗

NASA NTRS2021

Matrix Microcracking Effect on the Structural Response of a Thermal Protection System

The effect of microcracking in the phenolic matrix of a three-dimensional woven thermal protection system (TPS) and resulting material stiffness reduction was studied via a comparison of finite element results from linear and iterative linear analyses. A dual-layer continuous dry weave material with a low-density phenolic resin matrix has been developed for use in extreme environments. Due to high stresses in the through-the-thickness direction, microcracks may form in the matrix. The matrix does not have structural load transfer requirements, and testing has shown that microcracked phenolic resin satisfies thermal requirements. Microcracks in the matrix would result in a reduction of stiffness, which could alter the structural performance. A study was conducted to determine if reduction in material stiffness would change the load paths or structural margins. A linear finite element analysis that did not account for microcracking and an iterative linear finite element analysis that accounted for propagation microcracks were compared. Four subcases were analyzed with results indicating that the assumed propagation strength for the microcracking is the critical parameter for determining the extent of microcracking. Phenolic microcracking does not appear to have an adverse effect on the structural response and is not a critical failure for the modeled TPS.

Thermal Protection System↗

NASA NTRS2019

Compositional and Microstructural Effects in the Protection of SiC Components in Water Vapor

Greater gas turbine engine efficiency is a major goal in aeronautics research often pursued through increased engine operating temperatures. However, it is necessary to replace the current hot-stage alloy components with more thermally robust parts, such as promising Silicon-based ceramics and composites. Unfortunately, these materials are still susceptible to the effects of oxidation, water vapor, and (Calcium-Magnesium-Alumino-Silicate) CMAS interaction, among other issues at high temperature. To mitigate these effects, environmental barrier coating (EBC) materials are employed to help control the rate of degradation to the underlying composite. Often, a thermally grown oxide (TGO) layer forms between the EBC and the composite which can act as a point of failure. The current study focuses on the combined effects of water vapor, composite composition, and microstructure in TGO formation on protected and unprotected SiC samples which have been produced under different processing conditions.

Kowalski, Benjamin↗

NASA NTRS2008

Cooling Properties of the Shuttle Advanced Crew Escape Spacesuit: Results of an Environmental Chamber Experiment

The shuttle crew wears the Advanced Crew Escape Spacesuit (ACES) to protect themselves from cabin decompression and to support bail out during landing. ACES is cooled by a liquid-cooled garment (LCG) that interfaces to a heat exchanger that dumps heat into the cabin. The ACES outer layer is made of Gore-Tex(Registered TradeMark), permitting water vapor to escape while containing oxygen. The crew can only lose heat via insensible water losses and the LCG. Under nominal landing operations, the average cabin temperature rarely exceeds 75 F, which is adequate for the ACES to function. Problem A rescue shuttle will need to return 11 crew members if the previous mission suffers a thermal protection system failure, preventing it from returning safely to Earth. Initial analysis revealed that 11 crew members in the shuttle will increase cabin temperature at wheel stop above 80 F, which decreases the ACES ability to keep crew members cool. Air flow in the middeck of the shuttle is inhomogeneous and some ACES may experience much higher temperatures that could cause excessive thermal stress to crew members. Methods A ground study was conducted to measure the cooling efficiency of the ACES at 75 F, 85 F, and 95 F at 50% relative humidity. Test subjects representing 5, 50, and 95 percentile body habitus of the astronaut corps performed hand ergometry keeping their metabolic rate at 400, 600, and 800 BTU/hr for one hour. Core temperature was measured by rectal probe and skin, while inside and outside the suit. Environmental chamber wall and cooling unit inlet and outlet temperatures were measured using high-resolution thermistors ( 0.2 C). Conclusions Under these test conditions, the ACES was able to protect the core temperature of all test subjects, however thermal stress due to high insensible losses and skin temperature and skin heat flow may impact crew performance. Further research should be performed to understand the impact on cognitive performance.

Hamilton, Douglas↗

NASA NTRS1972

A numerical investigation of film cooling as an alternate thermal protection system for spacecraft during atmospheric reentry

Research was undertaken to determine the mass required to protect a surface during atmospheric reentry by injecting a cold gas tangentially along the surface. A consideration of this problem revealed that the boundary layer equations could be employed to approximate the most important flow configurations which occur in film cooling. However, even with this simplification, the equations to be solved are complex, nonlinear, coupled partial differential equations. Due to the relative weakness of classical methods of boundary layer analysis, finite difference methods were chosen as the best approach to the formidable problem under consideration. Instead of blindly adopting a proposed technique and trying to force it to the problem, a more systematic study was deemed to be not only desirable but necessary. A relatively basic study of the application of finite difference methods was undertaken with the objective of developing an algorithm capable of obtaining accurate solutions to film cooling problems.

Clausing, A. M.↗

NASA NTRS1981

An evaluation of computer codes for simulating the Galileo Probe aerothermal entry environment

The approaches of three computer flow field codes (HYVIS, COLTS, and RASLE), used to determine the Galileo Probe aerothermal environment and its effect on the design of the thermal protection system, are analyzed in order to resolve differences in their predicted results. All three codes account for the hypersonic, massively blown, radiation shock layers, characteristic of Jupiter entry. Significant differences, however, are evident in their solution procedures: the governing conservation equations, the numerical differencing methods, the governing physics (chemical, radiation, diffusion, and turbulence models), and the basic physical data (thermodynamic, transport, chemical, and spectral properties for atomic and molecular species). Solutions are compared for two near peak heating entry conditions for a Galileo Probe baseline configuration, having an initial mass of 242 kg and simulating entry into the Orton nominal atmosphere. The modern numerical methodology of COLTS and RASLE appear to provide an improved capability for coupled flow-field solutions.

Menees, G. P.↗

NASA NTRS1985

Design considerations for application of laminar flow control systems to transport aircraft

The current status of the laminar-flow control LFC technology is summarized. Factors that have previously inhibited the application of LFC are first reviewed. Involved are the effects of atmospheric ice crystals, surface irregularities, acoustical environment, and off-design operating conditions. Aircraft design trends that are different from turbulent aircraft are discussed as are various design requirements unique to the LFC systems. Current design approaches for the principal LFC systems are reviewed. These include the system for protection of the leading-edge region from surface contamination and icing and the system for removal of a portion of the boundary-layer air. The latter includes consideration of both multiple spanwise suction slots and distributed perforations and required differences between the wing-box and leading-edge box regions.

Braslow, A. L.↗

NASA NTRS2004

Experimental Aerothermodynamics In Support Of The Columbia Accident Investigation

The technical foundation for the most probable damage scenario reported in the Columbia Accident Investigation Board's final report was largely derived from synergistic aerodynamic/aerothermodynamic wind tunnel measurements and inviscid predictions made at NASA Langley Research Center and later corroborated with engineering analysis, high fidelity numerical viscous simulations, and foam impact testing near the close of the investigation. This report provides an overview of the hypersonic aerothermodynamic wind tunnel program conducted at NASA Langley and illustrates how the ground-based heating measurements provided early insight that guided the direction and utilization of agency resources in support of the investigation. Global surface heat transfer mappings, surface streamline patterns, and shock shapes were measured on 0.0075 scale models of the Orbiter configuration with and without postulated damage to the thermal protection system. Test parametrics include angle of attack from 38 to 42 degs, sideslip angles of 38 to 42 degs, sideslip angles of plus or minus 1 deg, Reynolds numbers based upon model length from 0.05 x 10(exp 6) to 6.5 x 10(exp 6), and normal shock density ratios of 5 (Mach 6 Air) and 12 (Mach 6 CF4). The primary objective of the testing was to provide surface heating characteristics on scaled Orbiter models with outer mold line perturbations to simulate various forms of localized surface damage to the thermal protection system. Initial experimental testing conducted within two weeks of the accident simulated a broad spectrum of thermal protection system damage to the Orbiter windward surface and was used to refute several hypothesized forms of thermal protection system damage, which included gouges in the windward thermal protection system tiles, breaches through the wing new the main landing gear door, and protuberances along the wing leading edge that produced asymmetric boundary layer transition. As the forensic phase of the investigation developed and the condition of recovered debris was examined, increasing emphasis was placed on identifying wing leading edge damage (partially and fully missing reinforced carbon-carbon panels, and eventually holes in the wing leading edge with venting to the wing upper surface) that produced off-nominal heating trends consistent with extracted Orbiter flight recorder temperature data.

Horvath, Thomas J.↗

NASA NTRS2018

Overview of Recent EAST Testing, Modeling & Analysis

Shock Layer Radiation at NASA Ames - Background: Complex aerothermal and thermochemical phenomena of planetary entry define convective and radiative heating. A spacecraft's TPS (Thermal Protective System) mitigates heat transfer to substructure. Successful TPS design relies on verifiable characterization of these phenomena in the anticipated flight environment. - Approach: EAST (Electric Arc Shock Tube) [facility at Ames] simulates high-enthalpy, real-gas phenomena encountered by hypersonic vehicles entering planetary atmospheres by spectrally imaging the flow behind a moving shock wave. - Goal: Validate aerothermal models (DPLR (Data Parallel Line Relaxation Code) and NEQAIR (Nonequilibrium Radiative Transport and Spectra Program)), inform model improvements, reduce uncertainty and quantify design uncertainties. - Recent Relevant Projects: MSL (Mars Science Laboratory) & Mars 2020, InSight, OSIRIS-REx (Origins Spectral Interpretation Resource Identification Security Regolith Explorer), Orion EFT-1 (Exploration Flight-1) and EM-1 (Exploration Mission-1) and New Frontiers.

Brandis, Aaron↗

NASA NTRSDate not supplied

Analysis of Hypervelocity-Impacted Thin Films for Space Applications

Exposure to the harsh space environment and hypervelocity impacts from micrometeoroids and small orbital debris can affect space operations through long-term degradation of spacecraft materials, surfaces, or systems. Multi-layer insulation (MLI) and coated polyimide films are space-craft materials commonly found on the external surfaces of spacecraft for thermal control and protection. Characterizing the damage to these exposed materials with in-situ and laboratory measurements can better inform spacecraft designers and operators in understanding and mitigating surface or system degradation. In this paper, we examine flown Hubble Space Telescope (HST) Electronic Bay 5 MLI and coated polyimide ground test articles to characterize hyper-velocity impact damage. Impact feature cavities are inspected to identify damage, which can validate long-term degradation models, improve thermal management systems, or improve accuracy of damage predictions. An overview of the impact characterization using optical microscopy, narrow-band spectroscopy, and scanning election microscopy/energy dispersive x-ray (SEM/EDX) of the two materials is presented. Observations of robustness in the space environment, as well as a detailed assessment of cratering and penetration statistics for the space-exposed sample, also are discussed.

Melissa A Ward↗

NASA NTRS2004

Improved BN Coatings on SiC Fibers in SiC Matrices

Modifications of BN-based coatings that are used as interfacial layers between the fibers and matrices of SiCfiber/SiC-matrix composite materials have been investigated to improve the thermomechanical properties of these materials. Such interfacial coating layers, which are also known as interphases (not to be confused with interphase in the biological sense), contribute to strength and fracture toughness of a fiber/matrix composite material by providing for limited amounts of fiber/matrix debonding and sliding to absorb some of the energy that would otherwise contribute to the propagation of cracks. Heretofore, the debonding and sliding have been of a type called inside debonding because they have taken place predominantly on the inside surfaces of the BN layers that is, at the interfaces between the SiC fibers and the interphases. The modifications cause the debonding and sliding to include more of a type, called outside debonding, that takes place at the outside surfaces of the BN layers that is, at the interfaces between the interphases and the matrix (see figure). One of the expected advantages of outside debonding is that unlike in inside debonding, the interphases would remain on the crack-bridging fibers. The interphases thus remaining should afford additional protection against oxidation at high temperature and should delay undesired fiber/fiber fusion and embrittlement of the composite material. A secondary benefit of outside debonding is that the interphase/matrix interfaces could be made more compliant than are the fiber/interphase interfaces, which necessarily incorporate the roughness of the SiC fibers. By properly engineering BN interphase layers to favor outside debonding, it should be possible, not only to delay embrittlement at intermediate temperatures, but also to reduce the effective interfacial shear strength and increase the failure strain and toughness of the composite material. Two techniques have been proposed and partially experimentally verified as candidate means to promote outside debonding in state-of-the-art SiC/SiC composites.

Morscher, Gregory N.↗

NASA NTRS1995

Effect of Cyclic Aeroconvective Heating on Flexible Thermal Insulations

This paper describes the effect of cyclic aeroconvective heating on the thermal performance of ceramic flexible insulations considered for potential use as thermal protection systems or thermal insulations for future hypersonic vehicles such as the Reusable Launch Vehicles (RLV's) and other applications where structures require thermal protection from severe heating. The thermal response of these materials after exposure to cyclic aeroconvective heating from a plasma arc is described. The thermal insulations evaluated were Composite Flexible Blanket Insulations composed of an outer layer of aluminoborosilicate fabric and alumina insulation. The insulations were evaluated with and without a high emissivity coating. These insulations were exposed to the plasma arc stream for nine minutes reaching surface temperatures of 1150 C and a heat flux of 10.5 W/sq cm. Insulations were exposed three, six, or nine times in order to demonstrate reusability and to determine the effect oi coatings on the surface durability of these insulations. Test results demonstrated the capability of these insulations to protect either composite or metallic structures from high heating environments. It is shown that high emittance coatings reduce backface temperatures. The durability of these insulations when impacted at low velocities was also demonstrated. The interaction of the coatings with the ceramic fibers was characterized. An analytical thermal model was utilized to correlate experimental thermal test results with calculated values.

Kourtides, Demetrius A.↗

DOE OSTI2022

DESIGN AND TESTING OF DIMES CARBON ABLATION RODS IN THE DIII-D TOKAMAK

We present the design of ATJ graphite rods developed for ablation experiments under high heat flux (up to 50 MW/m2) in the lower divertor of the DIII-D tokamak, a magnetic plasma confinement device. This work is motivated by the need to test ablation models relevant to carbon-based thermal shields used in high-speed spacecraft atmospheric entries, where the heat fluxes encountered can be comparable to those achieved in the DIII-D divertor plasma. Several different designs for the flowfacing side of the rod are analyzed, including "sharp nose," "blunt," and "concave". The last shape is studied for its potential to lower heat fluxes at the rod surface by increased radiation from trapped neutrals and reduced parallel plasma pressure. We also analyze the possibility of applying a thin (approximately 30 microns) layer of silicon carbide (SiC) to the exposed part of several carbon ablation rods to benchmark its erosion calculations and lifetime predictions. Such calculations are of interest as SiC represents a promising material for both thermal protection systems (TPS) and a fusion plasma-facing material (PFM). Preliminary results from the DIII-D rod ablation experiments are also discussed.

Orlov, Dmitri M.↗

NASA NTRS1977

Development and validation of purged thermal protection systems for liquid hydrogen fuel tanks of hypersonic vehicles

An economical, lightweight, safe, efficient, reliable, and reusable insulation system was developed for hypersonic cruise vehicle hydrogen fuel tanks. Results indicate that, a nitrogen purged, layered insulation system with nonpermeable closed-cell insulation next to the cryogenic tank and a high service temperature fibrous insulation surrounding it, is potentially an attractive solution to the insulation problem. For the postulated hypersonic flight the average unit weight of the purged insulation system (including insulation, condensate and fuel boil off) is 6.31 kg/sq m (1.29 psf). Limited cyclic tests of large specimens of closed cell polymethacrylimide foam indicate it will withstand the expected thermal cycle.

Helenbrook, R. D.↗

NASA NTRS2006

Advances in Hot-Structure Development

The National Aeronautics and Space Administration has actively participated in the development of hot structures technology for application to hypersonic flight systems. Hot structures have been developed for vehicles including the X-43A, X-37, and the Space Shuttle. These trans-atmospheric and atmospheric entry flight systems that incorporate hot-structures technology are lighter weight and require less maintenance than those that incorporate parasitic, thermal-protection materials that attach to warm or cool substructure. The development of hot structures requires a thorough understanding of material performance in an extreme environment, boundary conditions and load interactions, structural joint performance, and thermal and mechanical performance of integrated structural systems that operate at temperatures ranging from 1500 C to 3000 C, depending on the application. This paper will present recent advances in the development of hot structures, including development of environmentally durable, high temperature leading edges and control surfaces, integrated thermal protection systems, and repair technologies. The X-43A Mach-10 vehicle utilized carbon/carbon (C/C) leading edges on the nose, horizontal control surface, and vertical tail. The nose and vertical and horizontal tail leading edges were fabricated out of a 3:1 biased, high thermal conductivity C/C. The leading edges were coated with a three-layer coating comprised of a SiC conversion of the C/C, followed by a CVD layer of SiC, followed by a thin CVD layer of HfC. Work has also been performed on the development of an integrated structure and was focused on both hot and warm (insulated) structures and integrated fuselage/tank/TPS systems. The objective was to develop integrated multifunctional airframe structures that eliminate fragile external thermal-protection systems and incorporate the insulating function within the structure. The approach taken to achieve this goal was to develop candidate hypersonic airframe concepts, including structural arrangement, load paths, thermal-structural wall design, thermal accommodation features, and integration of major components, optimize thermalstructural configurations, and validate concepts through a building block test program and generate data to improve and validate analytical and design tools.

Rivers, H. Kevin↗

DOE OSTI2021

Silicon Anodes with Improved Calendar Life Enabled By Multivalent Additives

Silicon is widely recognized as the most promising upgrade for graphite anodes due to its much higher capacity, natural abundance, and ability to be directly applied in the slurry-based, roll-to-roll production lines. However, in addition to the fast capacity decay, silicon anodes also suffer from inferior calendar life in practical applications due to the unstable solid-electrode interface (SEI). Until now, strategies to effectively improve the calendar life by tailored SEIs remain largely unclear, especially in high-Si content, zero-graphite anodes. Here, silicon anodes with superior calendar life are developed by adding small concentrations of multivalent salts into the baseline electrolyte. The Ca additive reacts with the F ions in the electrolyte, forming a layer of nanocrystalline CaF 2 that is closely coated around the silicon particles. The CaF 2 -enabled new SEI is strong and dense, which effectively protects the silicon core from side reactions, leading to lower capacity decay after calendar aging at high voltage. More importantly, the Ca additive is effective universally for all available commercial silicon or SiO sources. This study provides a feasible and low-cost solution for developing silicon anodes with long calendar life, paving the way towards commercially viable silicon anodes.

25 ENERGY STORAGE↗

DOE OSTI2023

Effects of cathode loadings and anode protection on the performance of lithium metal batteries

Abstract While lithium-ion batteries (LIBs) are approaching their energy limits, lithium metal batteries (LMBs) are undergoing intensive investigation for higher energy density. Coupling LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) cathode with lithium (Li) metal anode, the resultant Li||NMC811 LMBs are among the most promising technologies for future transportation electrification, which have the potential to realize an energy density two times higher than that of state-of-the-art LIBs. To maximize their energy density, the Li||NMC811 LMBs are preferred to have their cathode loading as high as possible while their Li anode as thin as possible. To this end, we investigated the effects of different cathode active material loadings (2–14 mg cm −2 ) on the performance of the Li||NMC811 LMBs. Our study revealed that the cathode loadings have remarkably affected the cell performance, in terms of capacity retention and sustainable capacity. Cells with high cathode loadings are more liable to fade in capacity, due to more severe formation of the CEI and more sluggish ion transport. In this study, we also verified that the protection of the Li anode is significant for achieving better cell performance. In this regard, our newly developed Li-containing glycerol (LiGL) via molecular layer deposition (MLD) is promising to help boost the cell performance, which was controllably deposited on the Li anode.

Materials Science↗